Advanced instrument packaging for electronic energy meter

ABSTRACT

An electronic energy meter and its package is described in which the meter package has a reduced number of parts, and the main circuit board assembly has the metering electronics on board, thereby eliminating the need for flying leads and point-to-point wiring within the package. The energy meter includes a first enclosure portion, a circuit board assembly for performing metering functions, a partial terminal block, and a second enclosure portion. The first and second enclosure portions are mateable with each other to form a meter package, in which the circuit board assembly and partial terminal block are at least partially contained within the meter package.

RELATED APPLICATION DATA

[0001] The present application claims priority from provisionalapplication Serial No. 60/117,394, having a filing date of Jan. 27,1999.

FIELD OF THE INVENTION

[0002] The present invention relates generally to electronic energymeters, and more particularly to packaging for electronic energy meters.

BACKGROUND OF THE INVENTION

[0003] Programmable electronic energy meters are rapidly replacingelectro-mechanical meters due to the enhanced functionality achievedusing programmable logic integrated into solid-state electronic meters.Some of these meters can be used to meter various different electricalservices without hardware modification. For example, meters having avoltage operating range between 98 Vrms to 526 Vrms are capable ofoperation with either 120 V or 480 V services. U.S. Pat. No. 5,457,621,dated Oct. 10, 1995, entitled SWITCHING POWER SUPPLY HAVING VOLTAGEBLOCKING CLAMP, assigned to ABB Automation Inc. discloses examples ofsuch meters. In addition, some meters are constructed for use with any3-wire or any 4-wire service, also disclosed in U.S. Pat. No. 5,457,621.

[0004] However, many meters have complex packages that are difficult toassemble and which make it difficult to test the meter, leading toincreased costs and lower reliability. Therefore, there remains a needfor an electronic meter package that is easy to assemble, reliable, andpermits easy testing of the enclosed meter.

SUMMARY OF THE INVENTION

[0005] The present invention is directed to an electronic energy meterand its package. The meter package has a reduced number of parts, andthe main circuit board assembly has the metering electronics on board,thereby eliminating the need for flying leads and point-to-point wiringwithin the package. Thus, the meter package is mechanically simplifiedcompared to presently available meter packages, resulting in a lowercost and a more reliable meter contained therein.

[0006] According to aspects of the invention, the meter packagecomprises four primary parts, and eliminates the need for screw or rivettype fasteners. The only interconnections (electrical connectionsbetween the circuit board and metal hardware in the meter) areaccomplished by the use of a voltage spring between the circuit boardand the current bus conductors.

[0007] According to one aspect of the invention, current sensingelements are disposed on the circuit board. This allows currentconductors to be installed through the current sensors during themechanical assembly of the enclosure.

[0008] According to further aspects of the present invention, instead ofa separate component known as a terminal block, the present inventionhas features molded into the enclosure bottom half, along with amultifunction partial or upper terminal block to provide the desiredisolation between metal components.

[0009] According to another aspect of the invention, a serialized datalabel is incorporated into the package, thereby eliminating the need foradhesive and thus reducing overall production costs.

[0010] According to further aspects of the present invention, the meterfurther comprises a binocular that provides an uninterrupted linkbetween the meter and an external device. The binocular comprises twodirectional guides that are separated by a rib.

[0011] According to further aspects of the present invention, the meterfurther comprises an actuator switch or push button that can actuate orperform two functions with one button.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present invention will be better understood, and its numerousobjects and advantages will become apparent to those skilled in the artby reference to the following detailed description of the invention whentaken in conjunction with the following drawings, in which:

[0013]FIG. 1 is a schematic diagram of a meter assembly, exploded, inaccordance with the present invention;

[0014]FIG. 2 is a front view of an exemplary meter (with the wiringcover removed) in accordance with the present invention;

[0015]FIG. 3 is a top view of an exemplary circuit board assembly withcurrent sensors and current conductors in accordance with the presentinvention;

[0016]FIG. 4 is a side perspective view of an exemplary circuit boardassembly with current sensors and current conductors in accordance withthe present invention;

[0017]FIGS. 5A, 5B, 5C, and 5D are schematic diagrams at various viewsof an exemplary current conductor in accordance with the presentinvention;

[0018]FIG. 6 is a side perspective view of an exemplary current sensorassembly in accordance with the present invention;

[0019]FIG. 7 is a top view of an exemplary current sensor assembly withcircuit board assembly and partial terminal block in accordance with thepresent invention;

[0020]FIG. 8 is a side perspective view of an exemplary current sensorassembly with circuit board assembly, partial terminal block, and acontact spring in accordance with the present invention;

[0021]FIG. 9 is an opposing view of FIG. 8, with a cutaway portion ofthe circuit board;

[0022]FIG. 10 is a perspective view of an exemplary current sensorassembly with a contact spring in accordance with the present invention;

[0023]FIG. 11 is a perspective view of an exemplary contact spring inaccordance with the present invention;

[0024]FIG. 12 is a perspective view of an exemplary voltage disconnectlink in accordance with the present invention;

[0025]FIG. 13 is a cutaway side view of FIG. 12;

[0026]FIG. 14 is a schematic diagram showing an exemplary data labelincorporated into a meter package in accordance with the presentinvention;

[0027]FIG. 15 is a cross-sectional view of an exemplary data labelincorporated into a meter package in accordance with the presentinvention;

[0028]FIG. 16 is a front perspective view of an exemplary binocular inaccordance with the present invention;

[0029]FIG. 17 is a rear perspective view of an exemplary binocular inaccordance with the present invention;

[0030]FIG. 18 is a schematic diagram showing a binocular and anassociated circuit board assembly in accordance with the presentinvention;

[0031]FIG. 19 is a perspective view of an exemplary actuator switch(exploded) in accordance with the present invention;

[0032]FIG. 20 is a perspective view of an exemplary inner actuator of anactuator switch in accordance with the present invention;

[0033]FIG. 21 is a bottom perspective view of an exemplary inneractuator in accordance with the present invention;

[0034]FIG. 22 is a perspective view of an exemplary outer housing of anactuator switch in accordance with the present invention;

[0035]FIG. 23 is a perspective view of an exemplary actuator switch(assembled) in accordance with the present invention; and

[0036]FIG. 24 is a rear view of a portion of an exemplary secondenclosure portion in accordance with the present invention.

DESCRIPTION OF EXEMPLARY EMBODIMENTS AND BEST MODE

[0037] A perspective view (exploded) of an exemplary meter in accordancewith the present invention is shown in FIG. 1. The meter comprises afirst enclosure portion 10 and a second enclosure portion 20 thattogether form a case for containing the electrical components (e.g., acircuit board assembly 30). The meter further comprises a wiring cover40 that attaches to the second enclosure portion 20. A front view of anexemplary meter is shown in FIG. 2 (with the wiring cover 40 removed).

[0038] The first enclosure portion 10 acts as the rear or base of themeter and comprises terminal block features 12 that eliminate the needfor a complete separate terminal block. The terminal block features 12form voltage isolation barriers between the various metal parts atdifferent voltage potentials when they are encased in the assembly. Thisfunction works in conjunction with a partial terminal block 50 that isprovided. The partial terminal block 50 has similar features as theterminal block features 12 and has features designed to mesh in aninterlocking manner with the terminal block features 12 to form voltageisolation between the components it serves, while providing unrestrictedaccess to the internal metal components and ease of assembly. Thus,instead of a separate component known as a terminal block, the presentinvention has features 12 molded into the bottom portion of the firstenclosure portion 10, along with a multifunction partial or upperterminal block 50 to provide the desired isolation between metalcomponents. This arrangement provides superior performance bysimplifying the assembly steps, permitting simultaneous assembly inclamshell fashion around all the components, and, at the same time,yielding higher voltage creeping distances between components. The totalnumber of components is reduced because some of the metal parts arecombined into one.

[0039] The second enclosure portion 20 acts as the front or top of themeter and preferably comprises a semi-transparent material to eliminatethe need for a separate front cover. A window area 24 is provided forthe digital display 31 of the circuit board assembly and productnameplate, for example. The other areas of the second enclosure portion20 can be textured to provide a frosted appearance, thereby desirablyobscuring the view into the inside of the meter product. This eliminatesthe need to have windows of separate clear material attached to theenclosure 20 or a separate front cover, and reduces the number ofcomponents.

[0040] The circuit board assembly 30 contains the electrical componentsand circuitry for performing typical meter functions, such as thatdescribed in U.S. patent application Ser. No. 09/201,610, filed Nov. 30,1998, entitled ENERGY METER HAVING PROGRAMMABLE FUNCTIONS (AttorneyDocket No. ABME-0499), and incorporated herein by reference. Althoughthe electrical components and circuitry of the circuit board assembly 30can be any meter electrical components and circuitry that provide thedesired functionality, an exemplary circuit board assembly havingfeatures in accordance with the present invention is now described.

[0041] Preferably, the circuit board assembly 30 comprises toroidalcurrent sensors 33. As shown in FIG. 3, current sensors 33 are disposedat approximately 45-degree angles on the circuit board assembly 30. Thetoroidal current sensors 33 are mounted on the circuit board parallel toeach other, but at an approximately 45-degree angle to the edge of thecircuit board. This allows the current sensors 33 to be pre-installed onthe circuit board assembly 30 using any conventional technique such as awave solder technique. Although any current sensors can be used, currentsensors having current transformers having low permeability cores (e.g.,a permeability less than about 10,000 and preferably between about 1000and 10,000) that are nanocrystalline or amorphous are preferred. Anexample of preferred cores are amorphous cores manufactured byVacuumschmelze located in Germany. The advantage of this configurationis that it allows subsequent assembly of current conductors 35 throughthe center of each individual current sensor 33 after the currentsensors 33 are mounted on the circuit board assembly 30. Thisconfiguration eliminates point-to-point wiring and flying leads in theassembly, and provides a very compact assembly.

[0042] A current conductor 35 is inserted through the center of eachcurrent sensor 33, as shown in FIGS. 3 and 4. Each current conductor 35preferably comprises flat wires, instead of the conventional roundwires, thereby enhancing the contact surface area. Preferably, the wiresare formed, instead of stamped or punched, from a spool of flat wire,resulting in substantially zero waste. FIGS. 5A, 5B, 5C, and 5D showtop, side, front, and perspective views, respectively, of an exemplarycurrent conductor. The angular bends in the wire allow it to be used invery compact assembly while maintaining desired separation betweenconductors due to the flat thickness dimension being advantageouslyutilized.

[0043] The ends of the current conductor 35 are inserted into a wireclamp 14 and fastened by a wire clamp screw 15, as shown in FIG. 6. Thewire clamps are attached by conventional fasteners to the partialterminal block 50, as shown in FIGS. 7.

[0044] The toroidal current sensors 33 are disposed so that the currentconductors 35 are installed therethrough during the mechanical assemblyof the enclosure. In this manner, individual test probes can beimplemented for a current source while the current sensors 33, mountedin close proximity to each other for a more compact design, are mountedand electrically connected to the circuit board, effectively creating acomplete, working meter before final assembly in the enclosure portions10 and 20. This makes it possible to calibrate and test the “meter” as acircuit board, or component of the final assembly rather than only beingable to calibrate and test the meter after final assembly in theenclosure. Thus, rework of failed circuits is easier, and theopportunity is provided to perform final assembly in locations wheretesting and calibration equipment is not available.

[0045]FIG. 8 shows a front perspective view of the circuit boardassembly 30 attached to the partial terminal block 50 in accordance withthe present invention, and FIG. 9 shows an opposing perspective(cutaway) view. A flexible voltage contact spring 37 under stress andcompression acts as a spring connection and provides a wireless andsolderless voltage connection between current conductors 35 and thecircuit board assembly 30, thereby connecting the partial terminal block50 with the circuit board assembly 30. A side view of theinterconnection of the circuit board assembly 30 and the currentconductors is shown in FIG. 10.

[0046] An exemplary spring is shown in FIG. 11. The spring can compriseany material with adequate mechanical properties and electricalconductivity properties, such as stainless steel, phosphor bronze, orBe—Cu. Each contact area 38 of the spring is bifurcated 39 to yield aredundant contact point further enhancing the reliability of theconnection.

[0047] The spring 37 is an axially loaded leaf spring design that isused to make the voltage connection between the current phase input tothe circuit board assembly 30. This mechanical connection is designed tomaintain adequate contact pressure to result in a gastight electricalconnection under the environmental conditions the product is rated for.The spring design eliminates flying leads and point-to-point wiringwithin the meter assembly. This design greatly simplifies the physicalassembly of the product. As shown in FIG. 9, the spring 37 is retainedin the assembly 30 by features 52 molded into the terminal block upperhalf 50. No special tools are required for the assembly of these parts.

[0048] A voltage disconnect link is provided in an exemplary embodimentof the invention. The disconnect link of the present invention replacesremote wired hardware that is conventionally used as a voltagedisconnect link. The disconnect link is used to isolate current andvoltage sources during testing and calibration on some types of testequipment. The voltage disconnect link comprises voltage disconnectscrew 61, a voltage disconnect square nut 63, and a voltage disconnectslot 64 in the circuit board assembly 30, as shown in FIGS. 10, 12 and13. The circuit board assembly 30 has at least one voltage disconnectlink circuit pad 66 on a side of the voltage disconnect slot 64, and canhave more than one circuit pad 66 on the sides of the slot 64. Thevoltage disconnect screw 61 and the voltage disconnect square nut 63 areassembled to slide in the slot 64. At one end of the travel, the circuitpads 66 are shorted out by their contact with the screw assembly 61/63,thereby completing the voltage circuit. At the other extreme travelposition of the screw assembly 61/63 in the slot 64, the screw assembly61/63 resides in pocket 55 (preferably rectangular) that is preferablymolded into the terminal block upper half 50. The pocket 55 in theterminal block upper half 50 prevents the rotation of the nut 63 andallows the assembly to be locked in either the open or closed position(with respect to the circuitry). Therefore, the voltage can bedisconnected from a current source using this link assembly. To operatethe disconnect link, a screwdriver is used to loosen the screw about ½turn. At that point, the screw assembly 61/63 is free to slide in theslot 64 that it is assembled into. Also shown in FIGS. 12 and 13 is anauxiliary voltage connector 8.

[0049] Referring back to FIG. 1, the wiring cover 40 provides an accessport 42 that allows access to an internal power connection jack 32(disposed on the circuit board assembly 30, for example) in order topower up the meter for reading the stored data when the electricalservice to the meter is interrupted, for example. An access port cover44 is provided, and can comprise a weather resistant adhesive backedseal, for example, that is applied over the access port 42 in such amanner as to render the port impervious to dust and moisture, whileproviding tamper-evident and anti-tamper sealing. In order to access theinternal power jack 32, a meter reader pierces, breaks, or removes thecover 44, and inserts an external power plug that is part of an externalpower pack assembly (not shown) through the access port 42 into theinternal power connection jack 32. This permits the meter to be poweredup for a data exchange. Once this operation is complete, the cover 44can be replaced (or a new cover 44 applied) onto the wiring cover 40over the access port 42.

[0050] The components of the meter preferably snap together duringassembly, using tabs and grooves formed on the enclosure portions 10 and20, for example, thereby eliminating the need for any screws.Anti-tamper seal screws 22 can be provided, for example, if required bythe industry.

[0051] The arrangement of the components of the present inventionsimplifies the assembly steps, permitting simultaneous assembly in aclamshell fashion around the components, and, at the same time, yieldinghigher voltage creepage distances between components. The total numberof components is reduced because some of the metal parts can be combinedinto one.

[0052] The meter package has a reduced number of parts, and the maincircuit board assembly has the metering electronics on board, therebyeliminating the need for flying leads and point-to-point wiring withinthe package. Thus, the meter package is mechanically simplified comparedto presently available meter packages, resulting in a lower cost and amore reliable meter contained therein.

[0053] According to an embodiment of the invention, the second enclosureportion 20 comprises a serialized data label 26, as shown in FIG. 14.The data label 26 is preferably formed of a plastic, and has data (e.g.,meter serial number, specification information, etc.) directly printedthereon, by a thermal transfer technique, for example. The data labelcan have any desired dimensions and size, such as a rectangle that fitsbehind the window 24.

[0054] Preferably, the data label 26 snap-fits onto molded retainerfeatures 25 of the second enclosure portion 20 next to the window 24, sothat the data can be viewed through the window 24. The molded retainerfeatures can be ribs or grooves, for example. The second enclosureportion 20 preferably has a curved surface, as shown in FIG. 15, thatassists in retaining the snap-fit label and provides rigidity to theenclosure portion 20. The snap-fit eliminates the need for adhesivewhich prior art meter labels and nameplates rely on. Preferable materialfor the data label 26 is 0.010 ″ top coated DuPont polyester stock,manufactured by the DuPont, Wilmington, Del. Furthermore, because of thesnap-fit, tedious and careful placement of an adhesive-backed label isavoided.

[0055] For optical communication, a device called a binocular 16, asshown in FIGS. 1, 16, and 17, is used. The binocular 16 provides anuninterrupted link between the meter and an external device. Thebinocular comprises two directional guides 17 for LEDs 18 mounted on thecircuit board 30, as shown in FIG. 18, and separated by a rib 19.Preferably, the binocular 16 is molded out of an opaque resilientmaterial, such as a thermoplastic elastomer, although any material canbe used. The binocular 16 allows full contact between the secondenclosure portion 20 and the circuit board assembly 30, thereby ensuringmaximum shielding of ambient light. The rib 19 prevents crosstalkbetween the LEDs 18. Because the binocular 16 comprises a resilientmaterial, it is flexible and not rigid and compensates for variance intolerances of all the parts involved, thereby producing a good press fitunder a large variance. This also will act as a shock absorber for theassembly. It should be noted that the binocular 16 is more desirablethan using two separate, individual prior art light pipes to guide lightsignals because there is much less attenuation of the signal through theopen air of the binocular directional guides 17 than in the imperfecttransparent solids of conventional light pipes.

[0056] According to an embodiment of the invention, an actuator switchis incorporated into the meter. An exploded perspective view of anexemplary actuator switch 100 is shown in FIG. 19 (exploded) and FIG. 23(assembled). The actuator switch 100 can be used to actuate multipleconcealed switches of any kind. The switch 100 comprises an inneractuator 110 and an outer housing 120 that are assembled in the secondenclosure portion 20.

[0057]FIGS. 20 and 21 show a top view and a bottom view, respectively,of an exemplary inner actuator 110. An upper gap 114 in the ribs 115 ofthe inner actuator 110 corresponds with the locking-tab 126 on theinside of the outer housing 120 (FIG. 22). These features interlocktogether when the inner actuator 110 is inserted into the back of theouter housing 120. Specifically, these features interlock together whenthe inner actuator 110 is inserted into the back of the second enclosureportion 20 and the outer housing 120 is inserted into the front of thesecond enclosure portion 20. This keeps the assembly together and forcesthe inner actuator 110 and the outer housing 120 to travel up and downtogether. However, the inner actuator 110 is free to rotate within theouter housing 120. Both sides of the flange 117 that forms the uppersurface of the inner actuator 110 are designed to flex downward and giveway to the locking-tab 126. Referring to FIG. 22, the chamfer 128 on thebottom of the locking-tab 126 is designed to assist in the assemblyprocess while preventing disassembly. The hex area 129 inhibits theouter housing 120 from turning within the second enclosure portion 20.This also limits the downward travel of the actuator switch within thesecond enclosure portion 20.

[0058] Cantilevered spring features 130 are disposed on the bottom ofthe outer housing 120 that return the switch to its up position. Theactuator switch 100 is disposed through a hole 26 in the secondenclosure portion 20. FIG. 24 shows a rear view of a portion of thesecond enclosure portion 20. A boss 28 is disposed in the hole 26 on theback of the second enclosure portion 20 that limits the rotation of theinner actuator 110 to about 90 degrees either way. There are holes 122in the outer housing 120 and another hole 113 in the inner actuator 110that provide a way of sealing the actuator switch to a position where itwill not rotate. This is to isolate one of the functions while stillbeing able to actuate the other. There are two substantially flatflanges 116 on the bottom of the inner actuator 110. These arepreferably, but not be limited to, about 90 degrees apart. In this case,the flanges 116 interfere with associated tactile switches mounted on acircuit board. The drafting and coring features are present to reducematerial and make the parts easier to mold. Molded plugs 105 areprovided to prevent the rotation of the button without hampering theactuation of one of the switches. The slotted extension 118 on the topof the inner actuator 110 provides a way of turning assistance as with acoin or screwdriver.

[0059] Thus, the actuator switch can actuate or perform two functionswith one button;

[0060] i.e., it can activate two switches. First one switch isactivated, and then the actuator switch is turned 90 degrees, and asecond switch is activated. As described, the actuator switch isincorporated into the housing, and activates pads or switches on theunderlying circuit board assembly 30.

[0061] While the invention has been described and illustrated withreference to specific embodiments, those skilled in the art willrecognize that modification and variations may be made without departingfrom the principles of the invention as described hereinabove.

What is claimed is:
 1. An energy meter, comprising: a first enclosureportion; a circuit board assembly for performing metering functions; apartial terminal block; and a second enclosure portion, the first andsecond portions being mateable with each other to form a meter package,the circuit board assembly and partial terminal block at least partiallycontained within the meter package.
 2. The energy meter of claim 1,further comprising a wiring cover connected to the second enclosureportion.
 3. The energy meter of claim 1, wherein the first enclosureportion comprises a plurality of terminal block features.
 4. The energymeter of claim 1, wherein the second enclosure portion comprises asemi-transparent material.
 5. The energy meter of claim 1, wherein thesecond enclosure portion has a window area.
 6. The energy meter of claim1, wherein the circuit board assembly comprises a plurality of toroidalcurrent sensors.
 7. The energy meter of claim 6, wherein the currentsensors are disposed substantially in parallel with each other, and atapproximately 45-degree angles on the circuit board assembly withrespect to an edge of the circuit board assembly.
 8. The energy meter ofclaim 6, further comprising a plurality of current conductors, eachcurrent conductor disposed through an associated current sensor.
 9. Theenergy meter of claim 8, wherein each current conductor comprises a flatwire, and the ends of each wire are fastened to the partial terminalblock.
 10. The energy meter of claim 1, further comprising a contactspring connecting the circuit board assembly and the partial terminalblock.
 11. The energy meter of claim 10, wherein the contact springcomprises bifurcated ends.
 12. The energy meter of claim 1, wherein thecircuit board assembly further comprises a voltage disconnect link. 13.The energy meter of claim 12, wherein the voltage disconnect linkcomprises a voltage disconnect screw, a voltage disconnect square nut,and the circuit board assembly further comprises a voltage disconnectslot and a voltage disconnect link circuit pad on at least one side ofthe voltage disconnect slot.
 14. The energy meter of claim 13, whereinthe partial terminal block comprises a pocket for guiding the voltagedisconnect link.
 15. The energy meter of claim 1, further comprising adata label displaying data, the data label attached to the secondenclosure portion.
 16. The energy meter of claim 1, further comprising abinocular disposed between the second enclosure portion and the circuitboard assembly.
 17. The energy meter of claim 16, wherein the binocularcomprises two directional guides separated by a rib.
 18. The energymeter of claim 1, further comprising an actuator switch.
 19. The energymeter of claim 18, wherein the actuator switch comprises an inneractuator and an outer housing, the inner actuator connecting to theouter housing through the second enclosure portion.
 20. The energy meterof claim 19, wherein the inner actuator comprises ribs separated by atleast one gap, and the outer housing comprises a locking-tab, thelocking-tab corresponding to the at least one gap for interlocking. 21.A voltage disconnect link for isolating current and voltage sources inan energy meter having a circuit board assembly, comprising: a voltagedisconnect screw; a voltage disconnect square nut into which the voltagedisconnect screw is detachably mounted to form a screw assembly; avoltage disconnect slot disposed on the circuit board assembly, thescrew assembly slidably mounted therein; and a voltage disconnect linkcircuit pad on at least one side of the voltage disconnect slot.
 22. Thevoltage disconnect link according to claim 21, wherein at one end of thevoltage disconnect slot, the voltage disconnect link circuit pad isshorted out with the screw assembly.
 23. The voltage disconnect linkaccording to claim 21, wherein at one end of the voltage disconnectslot, the screw assembly is disposed in a pocket within the energymeter.
 24. The voltage disconnect link according to claim 23, whereinthe pocket prevents rotation of the voltage disconnect square nut.
 25. Abinocular for use in an energy meter, comprising: a first directionalguide; a second directional guide parallel to the first directionalguide, the first and second directional guides being hollow; and a ribdisposed between the first and second directional guides, the ribpreventing crosstalk between the first and second directional guides.26. The binocular according to claim 25, wherein the first and seconddirectional guides and the rib comprise an opaque resilient material.27. The binocular according to claim 26, wherein the opaque resilientmaterial is a thermoplastic elastomer.
 28. An actuator switchcomprising: an inner actuator comprises ribs separated by at least onegap; and an outer housing comprises a locking-tab, the locking-tabcorresponding to the at least one gap for interlocking.
 29. The actuatorswitch according to claim 28, wherein the inner actuator is rotatablewithin the outer housing.
 30. The actuator switch according to claim 28,wherein the inner actuator has an upper surface comprising a flangehaving two sides.
 31. The actuator switch according to claim 30, whereinthe both sides of the flange are flexible to give way to thelocking-tab.
 32. The actuator switch according to claim 28, wherein thelocking-tab comprises a chamfer.
 33. The actuator switch according toclaim 28, wherein the outer housing further comprises a hex area. 34.The actuator switch according to claim 28, where the outer housingfurther comprises a plurality of cantilevered springs.
 35. The actuatorswitch according to claim 28, wherein the inner actuator furthercomprises a plurality of substantially flat flanges.
 36. The actuatorswitch according to claim 35, wherein the flat flanges are about 90degrees apart.